MANAGEMENT OF CONSTRUCTION

EQUIPMENT FOR THERMAL POWER PROJECTS

REVIEW

GUIDED BY EFFORTS BY
MR KEDAR TAMBE NEHAL SHAH
OBJECTIVE
• To Study selection Procedure of different equipment
• Analysis of cost of mechanization for constructing a boiler unit at different sites and
calculating the cost /MW
• To Analyse the productivity of different equipment at different projects and Finding
Probable ways of Optimising the efficiency of the equipment

SCOPE OF WORK
The following are the equipment that will be studied at three different projects
1. Batching Plant
2. Transit Mixers
3. Truck mounted concrete pump
4. Crawler and wheel mounted Cranes
FACTORS AFFECTING SELECTION OF A CRANE
SR.NO FACTOR TYPE

1 Site Constraints

2 Site Topography

3 Access to Site
TECHNICAL
4 Site layout PARAMETRES

5 Weight and Size of material

6 Crane capabilities

7 Size and Number of cranes

8 Cranes Availability
ECONOMICAL
9 Running cost PARAMETRES

10 Purchase v/s Rent

CRANE SELECTION - MATRIX

SR.NO CRITERIA CRANE 1 CRANE 2 CRANE 3

Max Load Carrying
1
Capacity
2 Working Radius

3 Boom Length

4 Elevation

5 Owning Cost

6 Operation cost

7 Productivity
CASE STUDY DETAILS
• Project Name : 1 X 500 MW Ukai TPS extension –unit 6
• Total Capacity : 1350 MW
• Type of Project : Industrial
• End Use of the Project : Generation of Power
• Package under Study : (1 x 500 MW) Main plant and BOP civil works
• Total Cost of Packages : Rs.2200 CRORES
• Project start date : 17th November 2008
• Project Duration : 28 months
Bill Of Quantity –(Ukai Thermal Power Station)
ACTIVITY QUANTITY RATE (Rs) AMOUNT (IN LACS)

EXCAVATION CUM 170402.4 200 340.80

CUM
BACKFILLING CUM 113138.2 150 169.71
METALFILLING CUM 12986.05 1342 174.27
CONCRETE MT 79965.38 4600 3678.41
REINFORCEMENT SQM 8103.55 5000 405.18
SHUTTERING CUM 96551 350 337.93
BLOCK WORK SQM 3396.4 4000 135.86
PLASTER WORK MT 42636.65 200 85.27
FABRICATION & ERECTION MT 2826.95 36000 1017.70
OF STRUCTURAL STEEL
ERECTION OF STRUCTURAL SQM 6825 8000 546.00
STEEL
SLIPFORM SHUTTERING CUM 40827.5 1000 408.28
ACID BRICK WORK  CUM 677.25 28500 193.02
 VALUE WISE PIE CHART ( Ukai Thermal Power Station)

EXCAVATION BACKFILLING
METALFILLING CONCRETE
7% 3% 5%
2% REINFORCEMENT SHUTTERING
14%
5% 2% BLOCK WORK PLASTER WORK
1% FABRICATION & ERECTION ERECTION OF STRUCTURAL
2% 49% OF STRUCTURAL STEEL STEEL
5% SLIPFORM SHUTTERING ACID BRICK WORK
5%
 PLANT & MACHINERY

AVAILABLE AT SITE
SR. NO EQUIPMENT
OWNED HIRED TOTAL
1 Batching plant - 30 cum (Schwing Stetter) 2   1
2 Transit Mixer - 6 cum 6 4 10
3 Concrete Pump- 30 cum 1 1  2
4 Boom Placer- 30cum/hr
5 Excavator ( JCB ) -5D 1 3 4
6 Tractor with Trolley   5 5
7 Air Compressor– 175CFM   1 1
8 Hydra -14 Mt 2 2 4
9 Crawler Crane 75 Mt (40 ft boom length)  1 1 2
10 Crawler mounted Crane-180 MT  1 1
11 Trailer- 40ft (L)   3 3
FACTORS AFFECTING PRODUCTIVITY OF
EQUIPMENT
SR. CONDITIONS APL UMPP UTPE
NO
1 BATCHING PLANT  
AVAILIBILITY OF WORK  
POURING METHOD  
WEATHER CONDITIONS  
MANAGEMENT  
CONDITIONS
MECHANICAL  
CEMENT AND  
AGGREGATE DELIVERY

APL –Adani Power Limited : Appropriate

UMPP-Ultra Mega Power Project
UTPE-Ukai thermal Power Extension : Inappropriate
FACTORS AFFECTING PRODUCTIVITY OF EQUIPMENT

SR. CONDITIONS APL UMPP UTPE

NO
2 TRANSIT MIXERS  
PERIODICAL INSPECTION  
SERVICE AND OIL CHANGE  
DURATION
ROUTE OF TRANSIT MIXERS  

APL –Adani Power Limited : Appropriate

UMPP-Ultra Mega Power Project
UTPE-Ukai thermal Power Extension : Inappropriate
FACTORS AFFECTING PRODUCTIVITY OF EQUIPMENT

SR. CONDITIONS APL UMPP UTPE

NO
3 BOOM PLACERS  
PERIODICAL INSPECTION  
SERVICE AND OIL CHANGE  
DURATION
SOIL CONDITIONS  
CHECKING OF LINES  
TRAINED MANPOWER  
CLEANING OF HOSE PIPE  

APL –Adani Power Limited : Appropriate

UMPP-Ultra Mega Power Project
UTPE-Ukai thermal Power Extension : Inappropriate
FACTORS AFFECTING PRODUCTIVITY OF EQUIPMENT

SR. CONDITIONS APL UMPP UTPE

NO
4 CRAWLER CRANES  
SAFE LOAD INDICATOR  
SOIL CONDITIONS  
MOVING WITH LOAD  
MAINTENANCE PERIOD  
 
 

APL –Adani Power Limited : Appropriate

UMPP-Ultra Mega Power Project
UTPE-Ukai thermal Power Extension : Inappropriate
OWNED EQUIPMENT UTILIZATION
TOTAL TOTAL
SR. NO. EQUIPMENT NAME NOS. AVAILABLE WORKING TOTAL BREAK TOTAL IDLE UTILIZATION
DOWN HOURS HOURS (%)
HOURS HOURS
1 Batching Plant 2 3744 2465 514 760 65.84

2 Transit Mixer 6 11232 7100 691 2650 63.21

3 Boom Placer 1 1800 670 623 707 37.22

4 Cranes 2 3744 2214 370 1112.5 59.13

HIRED EQUIPMENT UTILIZATION

TOTAL TOTAL
TOTAL BREAK TOTAL IDLE UTILIZATION
SR. NO. EQUIPMENT NAME NOS. AVAILABLE WORKING
HOURS HOURS DOWN HOURS HOURS (%)

1 Transit Mixer 4 7488 4568 900 1240 61.00

2 Concrete Pump 1 1800 1340 268 132 74.44

3 Cranes 2 3744 1400 924 1420 37.39

OWNED EQUIPMENT UTILIZATION
Cranes
Batching Plant
TOTAL WORKING
HOURS 20% TOTAL AVAILABLE
30% HOURS
TOTAL WORKING
TOTAL BREAK DOWN HOURS
HOURS TOTAL BREAK
60% 14% DOWN HOURS
10% 66%
TOTAL IDLE HOURS

Transit Mixer
Boom Placer

TOTAL WORKING TOTAL WORKING

25% HOURS
35% 34% HOURS
TOTAL BREAK TOTAL BREAK
DOWN HOURS DOWN HOURS
TOTAL IDLE HOURS TOTAL IDLE
7% HOURS
68%
31%
 HIRED EQUIPMENT UTILIZATION
Cranes
Transit Mixer

TOTAL WORKING TOTAL WORKING

18% HOURS HOURS
TOTAL BREAK
38% 37%
TOTAL BREAK
DOWN HOURS DOWN HOURS
13% TOTAL IDLE TOTAL IDLE HOURS
HOURS
68%
25%

Concrete Pump
8%
TOTAL WORKING
15% HOURS
TOTAL BREAK
DOWN HOURS
TOTAL IDLE HOURS

77%
MONTHLY MAINTENANCE COST AND MONTHLY
BILL
MAINTENANCE MONTHLY BILL
SR.NO MONTH EXPENSE (RS IN LACS)
(RS IN LACS )

1 Oct-10 3.80 93.0

2 Nov-10 4.20 86.1

3 Dec-10 4.34 110.3

4 Jan-11 4.11 140.4

5 Feb-11 4.45 98.0

Note: Maintenance cost only includes equipment like :

Batching Plant, Transit Mixers, Boom placers, Crawler Cranes.
 RA BILL V/S MAINTENANCE OF EQUIPMENTS
160.0

140.0 140.4
AMOUNT IN LACS

120.0

110.3

100.0 98.0
93.0
86.1 MONTHLY BILL
80.0 MAINTENANCE EXPENSE

60.0

40.0

20.0

3.80 4.20 4.34 4.11 4.45

0.0
Oct-10 Nov-10 Dec-10 Jan-11 Feb-11
WORK METHODOLOGY TO CALCULATE COST OF
MECHANIZATION PER MW

Estimation of Quantities of
different activities

Operational hours for different

equipment

Owning and Operating cost for

respective equipment

Final cost
QUANTITIES FOR 1 BOILER UNIT

SR.NO MAIN ACTIVITY UNIT TATA ADANI UTP-

EXTENSION

1 PILING CUM 4680 0 0

PILE CAP AND

2 FOUNDATION CUM 1320 5600 5800
WORKS

3 EXCAVATION CUM 12000 14000 15000

4 STRUCTURAL TONNES
ERECTION 8153 7690 7260
Calculation of Cost of Mechanization – TATA Power
Plant
COST
SR.NO ACTIVITY EQUIPMENTS CAPACITY (OWNING AND
OPERATING)
1 PILING Hydraulic Rig 1248000
2 EXCAVATION Excavator 171430

3 CONCRETING Batching Plant 30 M3 /HR 500000

4 Transit Mixer 6 M3 357140

5 Boom Placer 30 M3 250000
STRUCTURAL
6 Crane hydra 14 TON
ERECTION
7 Crawler crane 50 TON
8 Crawler crane 70 TON 65224000

9 Crawler crane 150 TON

10 Trailer 20 TON
TOTAL 67750570
PER MW COST 84688/MW
Calculation of Cost of Mechanization–ADANI Power
Project
COST
SR.NO ACTIVITY EQUIPMENT CAPACITY (OWNING &
OPERATING)
1 EXCAVATION EXCAVATOR 1351000

2 CONCRETING BATCHING PLANT 30 M3 /HR 462000

3 TRANSIT MIXER 6 M3 504000

4 BOOM PLACER 30 M3 280000
STRUCTURAL
5 Crane hydra 14 TON
ERECTION
6 Crawler crane 50 TON
7 Crawler crane 70 TON 58444000

8 Crawler crane 150 TON

9 Trailer 20 TON

TOTAL  61041000

PER MW COST 76301.25

Calculation of Cost of Mechanization– UTP
Extension Unit-6
COST
SR.NO ACTIVITY EQUIPMENTS CAPACITY (OWNING &
OPERATING)
1 EXCAVATION EXCAVATOR 1485000

2 CONCRETING BATCHING PLANT 30 M3 /HR 461583.3333

3 TRANSIT MIXER 6 M3 502666.6667

4 BOOM PLACER 30 M3 276818.1818
STRUCTURAL
5 Crane hydra 14 TON
ERECTION
6 Crawler crane 50 TON
7 Crawler crane 70 TON 49368000

8 Crawler crane 150 TON

9 Trailer 20 TON
TOTAL 67750570
PER MW COST 84688/MW
 COMPARISON OF COST OF MECHANIZATION
90000
84557.61

80000
76301.25

70000
65117.59

60000

50000

40000

30000

20000

10000

0
TATA ADANI UTP-EXTENSION

Cost of Mechanization
 REMAINING WORK
• Time Analysis for Crawler Cranes
• Productivity Analysis
• Analysis of Maintenance manuals
 SCHEDULE OF REMAINING WORK
• Visit to Mundra : 8/04/11 to 11/04/11
Purpose :Data collection Determining Time analysis for crawler
cranes, Discussion with the Operator’s and maintenance
department.
• Analysis and Report Making: 12/04/12 to 19/04/12
REFERENCES
 
• ERA UKAI PROJECT DOCUMENTS
• MAINTENANCE MANUALS
• BOOKS- PEURIFOY “ CONSTRUCTION EQUIPMENT MANAGEMENT FOR
ESTIMATORS AND OWNERS “
 
THESIS
• MEHTA KSHITIJ, Management of Construction Equipment: Case Study Container
Berth Construction, Mundra
• ANUPAMA SHARMA, Management of Construction Equipment
• JIGNESH PARIKH, Management of Construction Equipment
• ANVI MANIAR, Management of Construction Equipment for port projects